Method of basement construction

ABSTRACT

A method of constructing an inhabitable underground structure is disclosed that comprises the steps: creating a cutout in the earth at a desired location to generally match a desired shape of an interior of the underground structure; applying a reinforcement structure to an outer perimeter of the cutout; and applying shotcrete over the reinforcement structure to create a monolithic underground structure.

PRIORITY CLAIM

This application is a Divisional of U.S. patent application Ser. No.14/149,175 filed Jan. 7, 2014, which is a Continuation of U.S. Pat. No.8,650,830 filed Mar. 8, 2013 and issued Feb. 18, 2014, which isincorporated herein by reference in its entirety.

BACKGROUND

1. Field of the Invention

This invention relates to a method of constructing an undergroundstructure, and more particularly to a method of construction of abasement that can be used as a foundation for the upper portion of thehouse.

2. Description of the Related Art

Basements have traditionally been constructed using either a concreteformed structure or a cinder block construction method, both of whichinvolve extensive labor and increase the cost substantially compared tothe construction cost of a typical slab foundation. Builders oftenlament that it is cheaper to go up than down. Nevertheless, there aresome benefits to having a basement, particularly in climates orgeographic regions where tornados or other weather events are likely tobe encountered.

In certain parts of the country and the world, basements are almostnon-existent because of conditions such as soil type. Clay soil, forexample, has the tendency to expand when wet, applying significantpressure to the walls of the basement that can cause cracking ormovement of the basement wall. For the same reason, the structure of thebasement may shift relative to other parts of the structure because itis typically made of different component parts. Generally, the floor ofthe basement is usually poured first and the walls of the basement aretypically poured on top of the floor after the floor has set.

There is a need for a new method of constructing a basement or otherunderground structure that is both cost efficient and reliable. It wouldbe desirable to have such a structure that is easy to construct and iscomparable in cost to pouring a traditional concrete slab foundation. Itwould also be desirable for the structure to be such that water andmoisture present in the basement are kept to a minimum.

SUMMARY

This summary is provided to describe certain aspects of exemplaryembodiments that can be practiced. It is not intended to show theessential features of the invention, nor is it intended to limit thescope of the claims of any issued patent.

In one exemplary embodiment, an underground structure is constructedusing the steps: creating a cutout in the earth at a desired location togenerally match a desired shape of an interior of the undergroundstructure; applying a reinforcement structure to an outer perimeter ofthe cutout; and applying shotcrete over the reinforcement structure tocreate a monolithic underground structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an underground structure in accordancewith an exemplary embodiment of the invention.

FIG. 2 is a top view of an underground structure in accordance with anexemplary embodiment of the present invention.

FIG. 3 is a cross-sectional view of an underground structure used as afoundation for a house in accordance with an exemplary embodiment of theinvention.

DETAILED DESCRIPTION

Referring now to FIG. 1, a perspective view of an underground structurein accordance with an exemplary embodiment of the invention isillustrated. The underground structure 100 is constructed from shotcretereinforced with traditional rebar, steel mesh and/or fibers. Shotcreteis pneumatically applied concrete and can be applied using either a wetmix or a dry mix. The term “gunite” is often used in the industry torefer to the dry-mix shotcrete process in which the dry cementiousmixture is blown through a hose to the nozzle, with water being injectedat the nozzle immediately before it exits the nozzle. The dry-mixprocess allows for effective placement in overhead and verticalapplications.

In one embodiment of the invention, the corners 105, 110, 115 of theunderground structure 100 are all rounded, including the transitionsbetween the walls and the floor. Moreover, the floor is also roundedsuch that a cross section of the floor can form the shape of an invertedarch to provide a more even distribution of the weight supported by thewalls of the structure through the floor of the structure.

To build the structure shown in FIG. 1, first a hole is excavated in theground generally in the shape desired for the underground structure.Although a rectangular shape is illustrated, the desired shape could beany shape desired by the end user although it is preferred that allcorners are rounded to avoid stress concentrations. Rebar or otherreinforcing means such as synthetic fiber is placed in the structurealong the walls and the floor of the structure to provide reinforcementand to serve as a guide for how thick the shotcrete should be applied. Aseparate wire or string can also be used to mark the inner surface ofthe underground structure to ensure that he walls and floor are ofsufficient thickness to support the loads for a given project. The rebaris formed in curved shapes to match the desired end shape of thestructure. Ideally, the re-bar should be constructed of one piecethrough the walls and floor of the structure and/or should be securedtogether to effectively create a single piece.

Several cutouts may also be formed in the structure to provide a meansof supporting both the floor beams 120 and the ceiling beams 125 of theunderground structure. Additionally, cutouts in the sidewalls of thewalls of the hole cut in the ground can be created such that pilasters130 are formed behind where the ceiling joist and floor joist will belocated to provide additional strength. The size of the rebar and thethickness of the shotcrete to be applied can be varied to meet thespecific structural requirements. Although not shown, a plurality ofpipes can be inserted through the walls and the floor at desiredlocations to allow for the creation of weep holes for the purpose ofallowing water to weep into the interior of the underground structure sothat it can be collected and drained into a suitable sump.

After the reinforcement structure is in place, dry concrete ispneumatically applied to the structure through a nozzle that mixes theconcrete with water. A plaster can be applied to the inner surfaces ofthe concrete to smooth out imperfections or alternatively can be left asis. The structure can be completed in a single application or multipleapplications could be utilized if a composite wall is desired.

Referring now to FIG. 2, a top view of an underground structure inaccordance with an exemplary embodiment of the present invention isillustrated. Wood beams 125 can be placed across the undergroundstructure by cutting the wood beam to fit between the cutouts 204 and206. The wood beams can rest on a traditional stud wall that is placedinside the underground structure (not illustrated) to support theceiling of the basement and the floor of the above-ground structure.Alternatively the beams can rest on the ledge of the cutouts 204, 206.The purpose of the pilasters 130 in FIG. 2 is to provide additionalstrength at the area which will receive more of the load as a result ofthe beams. This allows the structure to have an effective increasedthickness, thus creating a stronger structure. Alternatively, thethickness of the entire underground structure could be increased tosupport the desired load.

Referring now to FIG. 3, a cross-sectional view of the undergroundstructure 100 is illustrated. The structure having rebar 305 placedwithin it has generally upright walls 310 that are connected to aninverted arch-shaped bottom 315. The inverted arch 315 provides betterdistribution of weight than a structure with a slab or footings for thispurpose. Alternatively, the structure could be made with a flat bottomhaving rounded corners underneath the walls depending on the weight thatmust be supported by the walls. Floor beams 120 can be placed across thebottom of the structure and supported by ledges 320 formed in thestructure that keep the floor beams spaced away from the bottomstructure of the basement. The ledges can be sloped to help prevent theaccumulation of moisture underneath the beams. The edges of the beamscan also be spaced away from the wall to further aid in avoiding theaccumulation of moisture. In this manner, water that runs along theinside walls of the basement structure and collects at a low point inthe bottom of the basement structure, which can then be drained using asump through the drain 325. Alternatively, a sump pump can be placed atthe lowest point of the structure to evacuate water to a drain line.

To help prevent “floating” of the underground structure, weep holes 330can be placed in the bottom of the structure to allow water thatcollects underneath the structure to move to the inside of the structurewhere it can be drained away by the drain or a sump pump. The weep holesin one embodiment can be placed at the center of the bottom of thestructure as well as at a distance of approximately 6 feet from eachwall.

In addition to using the underground structure for traditional homeconstruction, the underground structure could also be placed underneathor adjacent a mobile home to allow a storm shelter for someone whoresides in a mobile home. The structure could also be used in astand-alone manner near an existing home. So instead of providingceiling beams for building up structure from the top of the basementstructure, a waterproof top can be placed on the structure with anopening that allows the occupant of the mobile home to enter theunderground stricture in the event of a storm.

Shotcrete is traditionally made at the construction site. Sand andportland cement are mixed together and a machine is used to shoot themixture onto the wall. The mixture can be semi-dry compared to pouring atraditional concrete foundation. This typically results in a strongerstructure because less water in the concrete mixture generally resultsin a stronger structure once the mixture has cured. There is also atendency when pouring traditional foundations and walls to wet themixture after it arrives at the site to make it easier to pour eventhough this is not a recommended practice. When it does happen, itresults in structures that are weaker than specified and the consequentfoundation cracking problems.

By utilizing the reinforced shotcrete construction method disclosedherein, home builders can save significant money in the construction ofa basement. This would lead to more home owners choosing to build abasement because it has benefits that are not available in homes withoutsuch a basement and the cost of going down into the ground to buildadditional living structures is now significantly cheaper.

While various embodiments in accordance with the principles disclosedherein have been described above, it should be understood that they havebeen presented by way of example only, and not limitation. Thus, thebreadth and scope of this disclosure should not be limited by any of theabove-described exemplary embodiments, but should be defined only inaccordance with any claims and their equivalents issuing from thisdisclosure. Furthermore, the above advantages and features are providedin described embodiments, but shall not limit the application of suchissued claims to processes and structures accomplishing any or all ofthe above advantages.

Additionally, the section headings herein are provided for consistencywith the suggestions under 37 CFR 1.77 or otherwise to provideorganizational cues. These headings shall not limit or characterize theinvention(s) set out in any claims that may issue from this disclosure.Specifically and by way of example, although the headings refer to a“Technical Field,” the claims should not be limited by the languagechosen under this heading to describe the so-called field. Further, adescription of a technology in the “Background” is not to be construedas an admission that certain technology is prior art to anyembodiment(s) in this disclosure. Neither is the “Summary” to beconsidered as a characterization of the embodiment(s) set forth inissued claims. Furthermore, any reference in this disclosure to“invention” in the singular should not be used to argue that there isonly a single point of novelty in this disclosure. Multiple embodimentsmay be set forth according to the limitations of the multiple claimsissuing from this disclosure, and such claims accordingly define theembodiment(s), and their equivalents, that are protected thereby. In allinstances, the scope of such claims shall be considered on their ownmerits in light of this disclosure, but should not be constrained by theheadings set forth herein.

1.-7. (canceled)
 8. A method of constructing an inhabitable structurehaving an underground portion comprising the steps: creating a cutout inthe earth at a desired location to generally match a desired shape ofthe underground portion; applying concrete to the cutout to create anunderground structure; forming an inner surface of the bottom of theunderground structure to have a concave curvature at a plurality ofcorners of the underground structure; and using a top side of theunderground structure as a foundation to support an above ground portionof the inhabitable structure.
 9. The method of claim 8 furthercomprising the step of placing a sump drain in the bottom of theunderground structure for draining moisture from the undergroundstructure.
 10. The method of claim 8 further comprising the step ofplacing a plurality of floor beams across a floor of the undergroundstructure by mounting the plurality of floor beams above a bottom of theunderground structure such that a resulting finished floor of theunderground structure is spaced apart from the bottom of the undergroundstructure to allow for draining of moisture between the finished floorand the underground structure.
 11. The method of claim 8 wherein abottom of the underground structure is shaped generally in the form ofan inverted arch.
 12. The method of claim 8 further comprising the stepusing a reinforcement system in the concrete.
 13. The method of claim 12wherein the reinforcement system is formed using rebar.
 14. The methodof claim 12 wherein the reinforcement system is formed using fiber mesh.15. The method of claim 12 wherein the concrete is applied using a drymix process.
 16. The method of claim 12 wherein the bottom of thereinforcement system is flat.
 17. An inhabitable structure having anunderground portion located within a cutout in the earth generallymatching a shape of the underground portion of the inhabitablestructure, the underground portion comprising: a plurality of walls anda bottom connected to the plurality of walls, each of the plurality ofwalls and the bottom formed of concrete to create an undergroundstructure; one or more transitions comprising concave curvatures locatedbetween one or more of the plurality of walls and the bottom of theunderground structure; and at least one top surface capable of acting asa foundation for an above ground portion of the inhabitable structure.18. The inhabitable structure of claim 17 further comprising a sumpdrain in the bottom of the underground structure for draining moisturefrom the underground structure.
 20. The inhabitable structure of claim17 further comprising a floor structure for supporting a finished floorand located over the bottom of the underground structure such that thefinished floor of the underground structure is spaced apart from thebottom of the underground structure to allow for draining of moisturebetween the finished floor and the underground structure and wherein thefloor structure comprises a plurality of floor beams across theunderground structure.
 21. The inhabitable structure of claim 20 whereinone or more ends of one or more of the plurality of floor beams areconnected to one or more of the plurality of walls of the undergroundstructure.
 22. The inhabitable structure of claim 3 wherein the one ormore ends of one or more of the plurality of floor beams are connectedto the walls using corresponding ledges located in the walls of theunderground structure.
 23. The inhabitable structure of claim 22 whereinthe ledges comprise cutouts formed into inner surfaces of one or more ofthe plurality of walls, and wherein the underground structure furthercomprises pilasters protruding from external surfaces of the wallsopposite the cutouts for increasing strength of the walls at thelocation of the cutouts.
 24. The inhabitable structure of claim 1wherein the bottom of the underground structure is shaped in the form ofan inverted arch.
 25. The inhabitable structure of claim 17 furthercomprising a reinforcement system located within the undergroundstructure.
 26. The inhabitable structure of claim 1 wherein thereinforcement structure comprises traditional rebar.
 27. The inhabitablestructure of claim 1 wherein the reinforcement structure comprises fibermesh.